Multilayer microporous separators for lithium ion secondary batteries and related methods

ABSTRACT

An improved multilayer laminated microporous battery separator for a lithium ion secondary battery, and/or a method of making or using this separator is provided. The preferred inventive dry process separator is a tri-layer laminated Polypropylene/Polyethylene/Polypropylene microporous membrane with a thickness range of 12 μm to 30 μm having improved puncture strength and low electrical resistance for improved cycling and charge performance in a lithium ion battery. In addition, the preferred inventive separator&#39;s or membrane&#39;s low Electrical Resistance and high porosity provides superior charge rate performance in a lithium battery for high power applications.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of co-pending U.S.provisional patent application No. 62/084,655, filed Nov. 26, 2014,which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

In accordance with at least selected embodiments, the present inventionor application is directed to novel or improved battery separators, basefilms or membranes, and/or methods of making and/or using suchseparators, films or membranes. In accordance with at least certainselected embodiments, the present invention or application is directedto novel or improved single or multilayer, co-extruded or laminatedmicroporous battery separators for lithium-ion secondary batteries,and/or methods of making and/or using such separators. In accordancewith at least particular embodiments, the invention is directed to novelor improved multilayer laminated microporous battery separators forlithium ion secondary batteries and/or methods of making and/or usingthis separator. The possibly preferred inventive dry process separatoris a tri-layer laminated Polypropylene/Polyethylene/Polypropylene(PP/PE/PP) microporous membrane with a thickness range of 12 μm to 30 μmhaving improved puncture strength and low electrical resistance forimproved cycling and charge performance in a lithium ion battery. Inaddition, the preferred inventive separator's or membrane's lowElectrical Resistance and high porosity provides superior charge rateperformance in a lithium battery for high power applications.

BACKGROUND OF THE INVENTION

Various methods exist to increase the mechanical strength of microporousseparator membranes for lithium ion secondary batteries. One such methodof improving the mechanical strength of a dry process microporousbattery separator membrane is discussed in U.S. Pat. No. 6,602,593. Thismethod is based on using a blow-up ratio (BUR) of at least 1.5 duringblown film extrusion. As known to one skilled in the art, a blow-upratio method involves a radial expansion of blown film from an annulardie. An increased level of crystalline structure orientation in thetransverse direction (TD) was achieved in the extruded membrane using ablow-up ratio equal to or greater than 1.5.

U.S. Pat. No. 8,795,565 describes a biaxial stretching techniqueinvolving both machine direction (MD) and TD stretching of a dry processprecursor membrane with a controlled MD relax process step. Biaxialstretched membranes have improved mechanical strength in the machinedirection (MD) and TD direction which may be predictive of excellentstrength performance when used as a battery separator membrane in alithium ion battery.

U.S. Pat. No. 8,486,556 discloses a multilayered battery separator withincreased strength as defined by the Mixed Penetration strength testmethod which is a measure of the force required to create a shortcircuit through a separator membrane. A high molecular weightpolypropylene resin with a melt flow index≦1.2 gram/10 minutes measuredat the polypropylene layer in the PP/PE/PP trilayer configuration of themultilayer separator membrane was used to produce the multilayeredseparator with thicknesses ranging from 21 to 24.5 μm, a porosityranging from 35% to 37%, an ASTM Gurley from 18 to 19 seconds(equivalent to a JIS Gurley=450 to 475 seconds), and ElectricalResistance (ER) (equivalent to the term Ionic Resistance, IR) rangingfrom 2.1 to 2.3 ohm-cm².

Also known are wet process microporous battery separators which are alsotypically biaxially stretched and may have fairly balanced MD and TDstrength properties. Examples of microporous membranes produced using awet process may be U.S. Pat. Nos. 5,051,183; 6,096,213; 6,153,133; and6,666,969.

Wet process battery separator membranes are manufactured using very highmolecular weights polymer resins which typically have a molecularweights greater than 500,000 and more preferably are greater than1,000,000 and require the use of a plasticizer(s) to allow meltextrusion. In addition, a component know as a plasticizer(s), typicallyoils, must be used in order for the very high molecular weight resins toundergo melt extrusion. The plasticizer must be extracted using solventsas part of the manufacturing process. The oil-plasticizer contaminatedsolvent from the extraction step of the manufacturing process must berecycled in order to bring the extracted solvent and oil to usablepurity quality. This is an additional energy cost that is expensive.Therefore, the wet process has the disadvantage of being a possiblyenvironmentally challenged process with costly solvent handling anddisposal issues when compared to the solvent-free, ‘green’, low impact,less expensive, dry process method.

The known methods of BUR blown film method, TD stretching of dry processmembranes and the wet process biaxial stretched porous membranes haveyet to achieve excellent strength performance properties in combinationwith a low Electrical Resistance (ER), not only <2 ohm-cm² ER range, butin the much lower and more preferred ER range of ≦1.3 ohm-cm².

Accordingly, there is a need for a dry process, solvent free,environmentally low impact process that produces a microporous batteryseparator or membrane with excellent cycle performance and safety in alithium ion battery. Battery manufacturers in the high powerapplications, for example, the Electric Drive Vehicle (EDV) industry,desire or require microporous battery separators with thicknessespreferably ranging from 14 to 30 μm, microporosity, with a high chargerate (C-rate) for optimal high energy performance. Furthermore, there isa need for a dry process microporous battery separator or membrane thatwill meet these requirements for EDV and Hybrid Electric Vehicle (HEV)battery systems.

SUMMARY OF THE INVENTION

In accordance with at least selected embodiments, aspects or objects,the present invention addresses the above needs and/or is directed tonovel or improved battery separators, base films or membranes, and/ormethods of making and/or using such separators, films or membranes. Inaccordance with at least certain selected embodiments, aspects orobjects, the present invention or application is directed to novel orimproved single or multilayer, co-extruded or laminated microporousbattery separators for lithium-ion secondary batteries, and/or methodsof making and/or using such separators. In accordance with at leastparticular embodiments, the invention is directed to novel or improvedmultilayer laminated microporous battery separators for lithiumbatteries, secondary or rechargeable lithium batteries, lithium ionsecondary batteries, and/or methods of making and/or using thisseparator. The possibly preferred inventive dry process separator is atri-layer laminated Polypropylene/Polyethylene/Polypropylene (PP/PE/PP)microporous membrane with a thickness range of 14 μm to 30 μm havingimproved puncture strength and low electrical resistance for improvedcycling and charge performance in a lithium battery. In addition, thepreferred inventive separator's or membrane's low Electrical Resistanceand high porosity provides superior charge rate (C rate) performance ina lithium battery for high power applications (such as EDV or HEV).

A novel microporous battery separator has been developed for use in alithium ion rechargeable battery. The possibly preferred inventiveseparator membrane, separator, base film or membrane is a dry processmulti-layer laminated microporous battery separator or membranecomprising a polypropylene/polyethylene/polypropylene (PP/PE/PP)trilayer configuration. The multilayer PP/PE/PP includes a thermalshutdown function provided by an inner PE layer. In addition, the outerPP layers provide excellent oxidation resistance for improved cyclingand trickle charge performance. The preferred polypropylene layers aremanufactured using a high molecular weight, low melt flow indexpolypropylene resin or a blend of high molecular weight, low melt flowindex polypropylene resins which, when extruded, do not require the useof plasticizers, and produces a precursor membrane with an internalmicrostructure having a high level of crystalline lamellae orientation.This high level of crystalline lamellae orientation in the PP layer ofprecursor membrane may play a critical role in the improved mechanicalstrength performance of the inventive separator porous membrane.Furthermore, the degree of crystallinity in the lamellae structure mayplay an integral role in the formation of the micropores during thestretching step in the manufacturing process of microporous separatormembranes, and has a major effect on the pore size and the percentporosity making up the overall microstructure of the porous layers inthe PP/PE/PP separator or membrane.

The inventive multilayer separator, base film (adapted to be coated orlaminated to other layers) or membrane can be prepared by the drystretch process (the CELGARD® dry process) which generally comprises:extruding separately PP and PE nonporous precursors, bonding togetherthe non-porous precursors in a PP/PE/PP stacked configuration to form abonded non-porous PP/PE/PP precursor, and stretching to form amicroporous multilayer membrane where pore formation results fromstretching a nonporous, semi-crystalline, extruded polymer precursor inthe machine (MD) direction.

The preferred inventive membrane with its combination of low ER, highporosity, low Gurley and high puncture strength has improved cycle lifeperformance and/or a higher level of safety in a lithium or lithium ionrechargeable battery for use in high power end use applications.

The increased crystalline structure orientation in the transversedirection (TD) achieved by the radially expansion of a blown extrudedprecursor film has been found to improve the mechanical strength,specifically TD tensile strength and TD elongation resulting in lesssplitting of the stretched microporous membrane in the machine direction(MD).

The exemplary inventive multilayer membrane, with a preferred thicknessrange of about 12 to 30 μm, has high charge rate performance whencompared to prior art battery separator membranes due to a combinationof high porosity≧38%, low electrical resistance≦1.5 ohm-cm² and low JISGurley≦320 sec/100 cc. Low ER and high porosity in a battery separatorleads to a higher level of ionic conductivity of the electrolyte and/orpromotes long cycle life in a lithium ion secondary battery.

In order to achieve low ER and high porosity, the inventive multilayerseparator membrane is preferably manufactured using a high molecularweight, low melt flow index polypropylene polymer resin which, when meltextruded using a dry process without the use of solvents and anextraction step, produces a high level of crystalline lamellae contentin the precursor membrane. When the precursor membrane having this highlevel of crystalline lamellae is stretched to make pores, the resultingmicroporous membrane exhibits increased puncture strength, low ER andhigh porosity. A separator should have significant mechanical strengthto endure the rigors of cell assembly and charge and discharge cyclesthroughout the lifetime of a battery. The inventive separator preferablyhas a puncture strength ranging from 330 gf at a thickness of 14 μm upto 549 gf at a thickness of 30 μm. The inventive dry process microporousbattery separator membrane preferably has equal or better separatorperformance properties between dry process and the wet process batteryseparator microporous membranes in terms of battery cycle life andsafety performance in a Lithium ion secondary battery.

In the dry process, the mode of pore formation in the stretching stepinvolves machine direction stretching which pulls apart stackedcrystalline lamellae plates, extending polymer fibrils and formingrectangular shaped pores. The amount of crystallinity in the lamellaestructure in the nonporous PP layer of the precursor membrane may be akey factor in the formation of internal porous microstructure of a dryprocess stretched microporous membrane. It is mentioned in X. M. Zhang,et. al., “Oriented Structure and Anisotropy Properties of Polymer BlownFilms HDPE, LLDPE and LDPE”, POLYMER 45 (2004) 217-229 and in S.Tabatabaei, et. al, “Microporous Membranes Obtained from PP/HDPEMultilayer Films by Stretching”, JMS 345 (2009) 148-159 that thestructure of the crystalline phase strongly influences the mechanicalproperties of films. When the inventive higher crystalline lamellaecontent precursor membrane is stretched to make pores, the resultingmicroporous membrane exhibits increased puncture strength, low ERtogether with a high level of porosity. Each of these factorscontributes to the high level of performance of the separator membranein terms of battery cycle life and safety in lithium ion secondarybatteries.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is an SEM Micrograph Surface view of an Etched PP MembraneShowing Uniform and Ordered Stacked Lamellar Structure.

FIG. 2 is Stress Strain plot of PP and HDPE Membranes.

FIG. 3 is SEM Micrograph of the Surface of CE 6 Microporous Film at20,000× Magnification.

FIG. 4 is SEM Micrograph of the Surface of CE 5 Microporous Film at20,000× Magnification.

FIG. 5 is a schematic diagram of chain folding in polypropylene and themolecular level polymer structure in the folds (See “The Theory ofBirefringence”, Cambridge Polymer Group, 2004, CPGAN #014,www.campoly.com).

FIG. 6 is SEM Micrograph of the Surface of inventive Ex. 2 Membrane.

FIG. 7 is SEM Micrograph of Cross Section View of Ex. 2 Membrane.

FIG. 8 is SEM Micrograph of the Surface of Ex. 3 Membrane.

FIG. 9 is SEM Micrograph of the Surface of Ex. 4 Membrane.

FIG. 10 is SEM Micrograph of the Surface of Ex. 5 Membrane.

FIG. 11 is SEM of Cross Section View of Ex. 5 Membrane.

FIG. 12 is Side by Side Comparison of Surface SEM Micrographs ofInventive Ex. 2, 3, 4 and 5 Membranes.

FIG. 13 is SEM Surface Micrograph of CE 1.

FIG. 14 is Electrical Resistance vs Thickness Plot.

FIG. 15 is Puncture Strength vs. Thickness Plot.

FIG. 16 is % Porosity vs. Thickness Plot.

DETAILED DESCRIPTION OF THE INVENTION

An exemplary novel or improved microporous battery separator has beendeveloped for use in a lithium battery such as a lithium ionrechargeable battery. The possibly preferred inventive separatormembrane is a dry process PP/PE/PP multi-layer microporous batteryseparator membrane manufactured using a high molecular weight and a lowmelt flow index polypropylene resin or a blend of high molecular weightand low melt flow index polypropylene resins (for at least the outerlayers) which, when extruded (without the need for plasticizers whichmust be extracted later), produces a precursor membrane with an internalmicrostructure having a high level of crystalline lamellae orientation.In addition, the internal microstructure has a high level of uniformityof crystalline lamellae structures which influences the microporeformation in the stretching step in a dry process.

FIG. 1 is an SEM micrograph of an etched PP nonporous membrane which hasa uniform and orderly stacked crystalline lamellar structure which hasnot undergone MD or TD stretching. The etching process was performed inorder to remove any amorphous portion to better allow visualization ofthe crystalline lamellae structure. A commonly known mode of poreformation in membranes is known and published in X. M. Zhang, et. al.,“Oriented Structure and Anisotropy Properties of Polymer Blown FilmsHDPE, LLDPE and LDPE”, POLYMER 45 (2004) 217-229 and in S. Tabatabaei,et. al, “Microporous Membranes Obtained from PP/HDPE Multilayer Films byStretching”, JMS 345 (2009) 148-159. FIG. 2 is a typical stress/strainplot showing the response of a nonporous membrane to applied stresswhere the pulling apart of the stacked crystalline lamellae plates withthe initial application of stress is depicted. This initial separationof the lamellae plates is followed by the further pulling out of thepolymer chains from the lamellar stack to form extended polymer chainstructures known as fibrils. FIG. 2 depicts further extension of polymerfibrils with applied stress to create the porous regions in themicrostructure,

FIGS. 3 and 4 are SEM micrographs showing the microscale appearance ofthe surface of microporous separator membranes CE 6 and CE 5. Thecrystalline lamellae and fibrillar structure are clearly visible at amagnification of 20,000×. A comparison of the crystalline lamellaeregions of CE 6 and CE 5 membranes demonstrates that CE 6 has thickercrystalline lamellae regions than CE 5.

FIG. 5 depicts chain folding in a polypropylene crystalline lamellaetogether a representation of the molecular level of polypropylenepolymer chains within the lamellae structure. (see “The Theory ofBirefringence”, Cambridge Polymer Group, 2004, CPGAN #014,www.campoly.com). Melt flow index (mfi or MFI), which is measured byweighing the mass of polypropylene polymer flow in a 10 minute timeperiod under a weight of 2.16 kg at 230 deg C., is an inherent propertyof a polymeric resin which is used in a melt flow extrusion process andis related to the molecular weight of a resin. Higher molecular weightPP will have lower mfi values.

Table 1 lists the melt flow index values of CE 6 and CE5 microporousmembranes together with the pore size of the resulting microporousmembrane produced from resins having the listed mfi values.

TABLE 1 Resin and Membrane Properties. ID mfi Pore size, μm CE 6 5.00.064 CE 5 1.5 0.04 Ex. 1-Ex. 6 0.8 0.029-0.038

CE 6 and CE 5 are produced using polypropylene resins of differentmolecular weights and melt flow indices (mfi) which may be criticalfactors in the development of the crystalline lamellae regions formedduring melt extrusion of the precursor membrane in a dry process.

CE 6 polypropylene resin has a mfi of 5.0 g/10 minutes which is morethan a 3× higher melt flow index (mfi) than the resin used tomanufacture CE 5 demonstrating a change in mfi value can have asignificant effect on the development of crystalline lamellae regionsand the uniformity of these crystalline lamellae regions in themicrostructure of a porous separator membrane.

EXAMPLES

Table 2. lists separator performance properties of twelve inventiveexamples Ex. 1-Ex. 12 (and for four comparative examples CE 1 to CE 4).The thickness of the inventive examples range from 14 μm to 30 μm whichis the preferred targeted thickness range for EDV application.

TABLE 2 Separator Membrane Properties. Thickness JIS Gurley ER % PP PorePS, μm sec/100 cc ohm-cm² Porosity Size, μm gf Ex. 1 14.4 320 1.2 39%0.029 330 Ex. 2 17.3 290 1.2 41% 0.031 350 Ex. 3 20 250 1.0 48% 0.038400 Ex. 4 20 320 1.3 47% 0.032 450 Ex. 5 25 320 1.2 50% 0.035 450 Ex. 630 350 1.4 53% 0.036 549 Ex. 7 12 230 1.1 42% 0.034 280 Ex. 8 14 210 1.044% 0.039 300 Ex. 9 16 250 0.9 50% 0.036 350 Ex. 10 18 250 1.1 44% 0.040380 Ex. 11 18 190 0.9 48.5%   0.048 360 Ex. 12 25 250 1.0 53% 0.045 420CE 1 16.7 316 1.5 41% 0.030 325 CE 2 25 620 2.5 39% 0.028 380 CE 3 20530 1.4 39% 0.027 360 CE 4 16 460 2.0 35% 0.032 250

The inventive separator membranes are produced using a high molecularweight polypropylene resin. When this higher crystalline resin is meltextruded, the resulting nonporous precursor membrane has a high level ofcrystalline lamellae orientation. Annealing and stretching of the highermolecular weight nonporous precursor membrane produces microporousmembranes with improved puncture strength at higher porosities and lowerER. An SEM micrograph of the PP surface of Inventive Ex. 2 shown in FIG.6 indicates a higher level crystalline lamellae content as noted by thethicker lamellae regions as compared to FIG. 3 (CE 6) and FIG. 4 (CE 5).Thicker lamellae may produce a mechanically stronger microporousmembrane.

SEM micrographs of Ex. 3, Ex. 4 and Ex. 5 are shown in FIGS. 8, 9 and10. The inventive examples described herein are thermal shutdownmicroporous membranes which contain a PE layer. FIG. 11 is a SEMmicrograph of a cross sectional view showing the trilayer PP/PE/PPconstruction of Inventive Ex. 2 where the thickness of each PP and PElayer are labeled in microns. The inner PE layer, which provides thermalshutdown at approximately 135 deg C., typically has larger pores thanthe outer PP layers. FIG. 12 provides a side by side comparison of SEMmicrographs of the surface of the Inventive examples Ex. 2, Ex. 3, Ex.4, and Ex. 5 demonstrating the higher content of crystalline content inthe internal microstructure of the membranes. The higher level ofcrystalline lamellae and uniformity of crystalline lamellae of theinventive examples is demonstrated in the SEM micrographs in FIG. 12.FIG. 13 is an SEM micrograph of the surface of the Comparative Example 1which has less uniform crystalline lamellae.

The amount and uniformity of crystalline lamellae in the inventivenonporous precursor membranes, together with the pore size and %porosity of the microporous separator membrane, may play a critical rolein separator performance properties such as Electrical Resistance,Gurley, and Puncture strength. Inventive membranes Ex. 1 through Ex. 12have Electrical Resistance (ER) values ranging from 0.9 to 1.4 atthicknesses ranging from 12 to 30 μm which provide high performancemicroporous membrane for EDV applications. The preferred inventivemicroporous membranes have low ER and low Gurley which are important inachieving excellent high rate performance in lithium batteries for EDVand other power applications when compared to prior art batteryseparator membranes.

FIG. 14 is a plot of ER in ohm-cm² as a function of membrane thicknessin μm of the inventive membranes Ex. 1 through Ex 12. The inventiveexamples have significantly lower ER than the comparative examples CE 1,2, 3 and 4. Furthermore, as the thickness of the inventive examplesincreases from 12 to 30 μm, the ER remains low at ≦1.5 ohm-cm². A low ERseparator membrane provides improved level of conductivity of thelithium ions during charge and discharge cycling in a lithium ionbattery adding to the overall performance of a battery.

FIG. 15 is a plot of Puncture strength as a function of thickness forthe inventive separator membrane Ex. 1 through Ex. 12. The inventivemembranes have higher puncture strength than the comparative examples CE1 through CE 4. Ex. 7, which is only 12 μm in thickness, has higherpuncture strength than CE 4, which is 16 μm thick. The inventivemembrane may better withstand the rigors of the winding process of thebattery assembly which may translate into improved mechanical strengthprotection against dendrite penetration during battery cycling. Acrossthe 12 μm to 30 μm range of thickness, the inventive membranes shown inFIG. 15 outperform the comparative art in terms of higher puncturestrength.

FIG. 16 is a plot of % porosity as a function of thickness of Inventivemembranes Ex. 1 through Ex. 12. The inventive membranes as compared tothe comparative examples CE 1 through CE 4 have higher percent porosityacross the 12 to 30 μm range of thickness and will perform better in alithium ion battery in terms of which electrolyte conductivity andelectrolyte retention.

Higher puncture strength, high percent porosity and low ER contribute tobetter cycle life and/or safety performance in a lithium ion battery,especially in high power applications.

In accordance with at least selected embodiments, aspects or objects,the present invention or application is directed to: An improvedseparator, membrane or base film as shown or described herein, and/orwherein the separator is a multilayer separator, membrane or base film,wherein the separator is a trilayer separator, membrane or base film,wherein the separator is made by a dry stretch process, wherein theseparator is made by a lamination process, wherein the separator has apuncture strength (PS) of at least 330 gf and has a thickness of atleast 14 μm, wherein the separator has a puncture strength (PS) of atleast 280 gf and has a thickness of at least 12 μm, wherein theseparator has a puncture strength (PS) of at least 350 gf and has athickness of at least 16 μm, wherein the separator has a porosity of atleast 35%, wherein the separator has a porosity of greater than 37%,wherein the separator has a porosity of at least 39%, wherein theseparator has a porosity in the range of about 35% to 65%, wherein theseparator has a porosity in the range of about 39% to 53%, wherein theseparator is especially well suited for power cells, such as used inelectric vehicles, wherein the separator has an ER of 1.5 ohm-cm² orless, has a porosity of at least 35%, and is adapted for a high C ratecharge and discharge, wherein the separator includes at least onemicroporous polyolefin membrane produced according to a dry process inwhich a polypropylene resin is extruded to form said membrane, saidresin having a melt flow index (MFI) of less than or equal to about 0.8grams/10 minute, and/or the like.

In accordance with at least selected embodiments, aspects or objects,the present invention or application is directed to: An improvedmultilayer separator, membrane or base film comprising:

at least one microporous membrane produced according to a dry stretchprocess in which a polyolefin resin, mix or blend is extruded to formsaid membrane, said resin having a melt flow index (MFI) of less than orequal to about 0.8 grams/10 minute; and

wherein said separator having a thickness of greater than or equal toabout 14 μm, a porosity in the range of about 35% to about 65%, and anelectrical resistance (ER) value of less than or equal to about 1.5ohm-cm², and

optionally wherein the separator is a trilayer separator or base film,is made by a dry stretch process, is made by a lamination process, has apuncture strength (PS) of at least 280 gf and has a thickness of atleast 12 μm, has a puncture strength (PS) of at least 330 gf and has athickness of at least 14 μm, has a puncture strength (PS) of at least350 gf and has a thickness of at least 16 μm, has a porosity of at least35%, has a porosity of greater than 37%, has a porosity of at least 39%,has a porosity in the range of about 35% to 65%, has a porosity in therange of about 39% to 53%, is especially well suited for power cells,such as used in electric vehicles, has an ER of 1.5 ohm-cm² or less, hasa porosity of at least 35%, and is adapted for a high C rate charge anddischarge, includes at least two microporous polyolefin membranesproduced according to a dry process in which a polypropylene resin isextruded to form said membrane, said resin having a melt flow index(MFI) of less than or equal to about 0.8 grams/10 minute, includes atleast three microporous polyolefin membranes produced according to a dryprocess in which a polypropylene resin is extruded to form saidmembrane, said resin having a melt flow index (MFI) of less than orequal to about 0.8 grams/10 minute, includes at least one polyethylenemembrane, includes at least two polypropylene membranes, and/or havingan improved puncture strength over prior separators of the samethickness, and/or the like.

In accordance with at least selected embodiments, aspects or objects,the present invention or application is directed to: A multilayerseparator as shown or described herein having an improved puncturestrength over prior multilayer separators of the same thickness.

In accordance with at least selected embodiments, aspects or objects,the present invention or application is directed to: A trilayerseparator as shown or described herein having an improved puncturestrength over prior trilayer separators of the same thickness.

In accordance with at least selected embodiments, aspects or objects,the present invention or application is directed to novel or improvedbattery separators, base films or membranes, and/or methods of makingand/or using such separators, films or membranes. In accordance with atleast certain selected embodiments, aspects or objects, the presentinvention or application is directed to novel or improved single ormultilayer, co-extruded or laminated microporous battery separators forlithium-ion secondary batteries, and/or methods of making and/or usingsuch separators. In accordance with at least particular embodiments, theinvention is directed to novel or improved multilayer laminatedmicroporous battery separators for lithium ion secondary batteriesand/or methods of making and/or using this separator. The possiblypreferred inventive dry process separator is a tri-layer laminatedPolypropylene/Polyethylene/Polypropylene (PP/PE/PP) microporous membranewith a thickness range of 14 μm to 30 μm having improved puncturestrength and low electrical resistance for improved cycling and chargeperformance in a lithium ion battery. In addition, the preferredinventive separator's or membrane's low Electrical Resistance and highporosity provides superior charge rate performance in a lithium batteryfor high power applications.

An improved multilayer laminated microporous battery separator for alithium ion secondary battery, and/or a method of making or using thisseparator is provided. The preferred inventive dry process separator isa tri-layer laminated Polypropylene/Polyethylene/Polypropylenemicroporous membrane with a thickness range of 14 μm to 30 μm havingimproved puncture strength and low electrical resistance for improvedcycling and charge performance in a lithium ion battery. In addition,the preferred inventive separator's or membrane's low ElectricalResistance and high porosity provides superior charge rate performancein a lithium battery for high power applications.

TEST METHODS Thickness

Thickness is measured using the Emveco Microgage 210-A precisionmicrometer thickness tester according to test procedure ASTM D374.Thickness values are reported in units of micrometers, μm.

Puncture Strength

Test samples are first pre-conditioned to 73.4 deg C. and a relativehumidity of 50% for a minimum of 20 minutes. An Instron Model 4442 isused to measure puncture strength of test sample. Thirty measurementsare made across the diagonal direction of a 1¼″×40″ continuous samplespecimen and averaged. The needle has a 0.5 mm radius. The rate ofdescent is 25 mm/min. The film is held tight in a clamping device whichutilizes an O-ring to securely hold the test sample in place. Thediameter of this secured area is 25 mm. The displacement (in mm) of thefilm that was pierced by the needle is recorded against the resistanceforce (in gram force) developed by the tested film. The maximumresistance force is the puncture strength in units of gram force (gf). Aload-versus-displacement plot is produced by this test method.

Pore Size

Pore size is measured using the Aquapore available through PorousMaterials, Inc. (PMI). Pore size is expressed in μm.

Porosity

The porosity of a microporous film sample is measured using ASTM methodD-2873 and is defined as the percent void spaces in a microporousmembrane.

TD and MD Tensile Strength

The tensile strength along the MD and TD is measured using Instron Model4201 according to ASTM D-882 method.

Melt Flow Index (MFI)

Melt flow index of a polymer resin is measured using ASTM DS 1238; Formeasuring MFI of Polyethylene: Temperature=190° C. using weight 2.16 kg;for Polypropylene: Temperature=230° C. using weight 2.16 kg. MFI ismeasured as grams/10 minutes.

Electrical Resistance (ER) (Also Known as Ionic Resistance, IR)

Electrical Resistance is defined as the Resistance value in ohm-cm2 of aseparator filled with electrolyte. The units of electrical resistanceare ohm-cm². The separator resistance is characterized by cutting smallpieces of separators from the finished material and then placing thembetween two blocking electrodes. The separators are saturated with thebattery electrolyte with 1.0 M LiPF₆ salt in EC/EMC solvent of 3:7 ratioby volume. The Resistance, R, in Ohms (Ω), of the separator is measuredby a 4-probe AC impedance technique. In order to reduce the measurementerror on the electrode/separator interface, multiple measurements areneeded by adding more layers. Based on the multiple layer measurements,the electric (ionic) resistance, R_(s) (Ω), of the separator saturatedwith electrolyte is then calculated by the formula R_(s)=p_(s)1/A wherep_(s) is the ionic resistivity of the separator in Ω-cm, A is theelectrode area in cm² and 1 is the thickness of the separator in cm. Theratio p_(s)/A=is the slope calculated for the variation of the separatorresistance (ΔR) with multiple layers (Δδ) which is given byslope=p_(s)/A=ΔR/Δδ.

In accordance with at least selected embodiments, aspects or objects, anovel or improved multilayer laminated microporous battery separator fora lithium ion secondary battery, and/or a method of making and/or usingthis separator is provided. The preferred inventive dry processseparator is a tri-layer laminatedPolypropylene/Polyethylene/Polypropylene microporous membrane with athickness range of 14 μm to 30 μm having improved puncture strength andlow electrical resistance for improved cycling and trickle charge orcharge performance in a lithium ion battery. In addition, the preferredinventive separator's or membrane's low Electrical Resistance and highporosity provides superior charge rate performance in a lithium batteryfor high power, EDV or HEV applications.

The present invention may be embodied in other forms without departingfrom the spirit and the essential attributes thereof, and, accordingly,reference should be made to the appended claims, rather than to theforegoing specification, as indicating the scope of the invention.Additionally, the invention disclosed herein suitably may be practicedin the absence of any element which is not specifically disclosedherein.

We claim:
 1. A novel or improved separator, membrane or base film havingat least one of: at least one microporous membrane produced according toa dry stretch process in which a polyolefin resin, mix or blend isextruded to form said membrane, said resin having a melt flow index(MFI) of less than or equal to about 0.8 grams/10 minute; and whereinsaid separator having a thickness of greater than or equal to about 12μm, a porosity in the range of about 35% to about 65%, and an electricalresistance (ER) value of less than or equal to about 1.5 ohm-cm², andoptionally wherein the separator is a multilayer or trilayer separatoror base film, is made by a dry stretch process, is made by a laminationprocess, has a puncture strength (PS) of at least 280 gf and has athickness of at least 12 μm, has a puncture strength (PS) of at least330 gf and has a thickness of at least 14 μm, has a puncture strength(PS) of at least 350 gf and has a thickness of at least 16 μm, has aporosity of at least 35%, has a porosity of greater than 37%, has aporosity of at least 39%, has a porosity in the range of about 35% to65%, has a porosity in the range of about 39% to 53%, is especially wellsuited for power cells, such as used in electric vehicles, has an ER of1.5 ohm-cm² or less, has a porosity of at least 35%, and is adapted fora high C rate charge and discharge, includes at least two microporouspolyolefin membranes produced according to a dry process in which apolypropylene resin is extruded to form said membrane, said resin havinga melt flow index (MFI) of less than or equal to about 0.8 grams/10minute, includes at least three microporous polyolefin membranesproduced according to a dry process in which a polypropylene resin isextruded to form said membrane, said resin having a melt flow index(MFI) of less than or equal to about 0.8 grams/10 minute, includes atleast one polyethylene membrane, includes at least two polypropylenemembranes, and/or having an improved puncture strength over priorseparators of the same thickness, and combinations thereof.
 2. Theseparator of claim 1 wherein the separator is a multilayer separator,membrane or base film.
 3. The separator of claim 1 wherein the separatoris a trilayer separator, membrane or base film.
 4. The separator ofclaim 1 wherein the separator is made by a dry stretch process.
 5. Theseparator of claim 1 wherein the separator is made by a laminationprocess.
 6. The separator of claim 1 wherein the separator has apuncture strength (PS) of at least 330 gf and has a thickness of atleast 14 μm.
 7. The separator of claim 1 wherein the separator has apuncture strength (PS) of at least 350 gf and has a thickness of atleast 16 μm.
 8. The separator of claim 1 wherein the separator has aporosity of at least 35%.
 9. The separator of claim 1 wherein theseparator has a porosity of greater than 37%.
 10. The separator of claim1 wherein the separator has a porosity of at least 39%.
 11. Theseparator of claim 1 wherein the separator has a porosity in the rangeof about 35% to 65%.
 12. The separator of claim 1 wherein the separatorhas a porosity in the range of about 39% to 53%.
 13. The separator ofclaim 1 wherein the separator is especially well suited for power cells,such as used in electric vehicles.
 14. The separator of claim 1 whereinthe separator has an ER of 1.5 ohm-cm² or less, has a porosity of atleast 35%, and is adapted for a high C rate charge and discharge. 15.The separator of claim 1 wherein the separator includes at least onemicroporous polyolefin membrane produced according to a dry process inwhich a polypropylene resin is extruded to form said membrane, saidresin having a melt flow index (MFI) of less than or equal to about 0.8grams/10 minute.
 16. A novel or improved multilayer separator, membraneor base film comprising: at least one microporous membrane producedaccording to a dry stretch process in which a polyolefin resin, mix orblend is extruded to form said membrane, said resin having a melt flowindex (MFI) of less than or equal to about 0.8 grams/10 minute; andwherein said separator having a thickness of greater than or equal toabout 14 μm, a porosity in the range of about 35% to about 65%, and anelectrical resistance (ER) value of less than or equal to about 1.5ohm-cm², and optionally wherein the separator is a trilayer separator orbase film, is made by a dry stretch process, is made by a laminationprocess, has a puncture strength (PS) of at least 330 gf and has athickness of at least 14 μm, has a puncture strength (PS) of at least350 gf and has a thickness of at least 16 μm, has a porosity of at least35%, has a porosity of greater than 37%, has a porosity of at least 39%,has a porosity in the range of about 35% to 65%, has a porosity in therange of about 39% to 53%, is especially well suited for power cells,such as used in electric vehicles, has an ER of 1.5 ohm-cm² or less, hasa porosity of at least 35%, and is adapted for a high C rate charge anddischarge, includes at least two microporous polyolefin membranesproduced according to a dry process in which a polypropylene resin isextruded to form said membrane, said resin having a melt flow index(MFI) of less than or equal to about 0.8 grams/10 minute, includes atleast three microporous polyolefin membranes produced according to a dryprocess in which a polypropylene resin is extruded to form saidmembrane, said resin having a melt flow index (MFI) of less than orequal to about 0.8 grams/10 minute, includes at least one polyethylenemembrane, includes at least two polypropylene membranes, and/or havingan improved puncture strength over prior separators of the samethickness.
 17. The separator of claim 16 having an improved puncturestrength over prior multilayer separators of the same thickness.
 18. Theseparator of claim 16 being a trilayer separator having an improvedpuncture strength over prior trilayer separators of the same thickness.